The fault is one of the key factors that restricts the stability of surrounding rock masses in underground caverns. A comprehensive method including theoretical analysis, numerical simulation, and field investigation was conducted to investigate the failure mechanisms and control strategy of fault based on the underground cavern of the Kala (KL) hydropower station in Southwest China. Firstly, a mechanical failure criterion of fault failure was derived based on Anderson’s fault stress model and the Mohr-Coulomb criterion. Then, discrete element numerical software 3DEC was used to reveal the evolution process of fault slip and the influence mechanisms of system parameters, including shear stiffness, fault dip angle, and shear strength. Finally, a support and control strategy for fault stability was proposed based on the fault instability failure mechanism, which was implemented in the field. The results indicate that fault stability increases with increasing internal friction angle, cohesion, and minimum principal stress, but decreases with increasing maximum principal stress. The fault slip process exhibits three distinct successive stages: slow growth, rapid evolution, and stable equilibrium. Numerical results show that fault slip displacement follows a nonlinear trend with increasing dip angle (increasing first and then decreasing) and decreases significantly with higher shear stiffness and internal friction angle. A synergistic support strategy including “precision blasting + timely support” and “shotcrete + prestressed rockbolt + prestressed cables” was proposed based on the fault failure mechanism, which significantly reduces the risk of fault instability activation. Field monitoring indicates that the support scheme significantly reduces the tendency for fault instability, enhancing the stability of the surrounding rock.
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